DESIGN OF EQUIPMENTS

ABSORBER

PROCESS DESIGN OF ABSORBER:

BASIS:

1 HOUR OF OPERATION

COMPOSITION OF THE INCOMING GAS:

COMPONENT AMOUNT IN KMOLES MOLE FRACTION

N2 3298.32 0.8301 SO3 403.732 0.1016 SO2 13.777 0.00346 O2 257.395 0.06478 TOTAL 3973.23 1.0

Avg Mol Wt = [28 x 3298.32 + 32 x 257.395 + 64 x 13.778 + 80 x 403.7] / 3973.23 = 33.6 Kg/Kmoles

Inlet temperature of the gas =110 C

Density of the gas = [ 33.6 x 273 ] / { 22.4 x 383 } = 1.0711 Kg/m3

Sulfur Trioxide is absorbed in 98% sulphuric acid and the gases after absorption are returned back to the converter. The exit concentration of the acid is assumed to be 103% (3% free oleum)

Assuming negligible absorption of the other gases and at the average temperature of the gas inside the tower at 95 C,

Moles of SO3 at the exit = 158.014

SO3 to be absorbed = 403.732 - 158.014 = 245.718 Kmoles = 19657.5 Kgs

Water required to absorb SO3 = 245.72 x 18 = 4422.96 Kgs

Water present in incoming gas = 110.98 Kmoles Sulfuric acid formed = 110.98 Kmoles

= 10876.04 Kgs

Free SO3 with it = 326.3 Total SO3 absorbed by water = 110.98 x 80 + 326.3 = 9204.7 Kgs

SO3 to be absorbed in 98% acid = 19657.5 9204.7 = 10452.8 Kgs

Let W be the weight of 98% acid used in the tower, Then, SO3 absorbed by it = [W x 0.02 x 80] / 18 Total weight of 100% acid = W + { [W x 0.02 x 80] / 18 } = 1.0889 W

Free SO3 associated with it = 0.03 x 1.0889 W = 0.03267 W Total Weight = (1.0889 + 0.03267) W = 1.12157 W Kgs of SO3 absorbed by W Kgs = 1.12157 W W = 0.12157 W

Now, For 0.12157 W = 10452.8 Kgs then, For W = 85982 Kgs acid / Hr = 23.88 Kgs/s

Thus, Liquid flow rate is given as, L = 23.88 Kgs/s 'HQVLW\ !L) = 1850 Kg/m3

Gas Flow Rate = [3973.23 x 33.6] / 3600 = 37.08 Kgs/s

G = 37.08 Kgs/s 'HQVLW\ !G) = 1.0711 Kg/m3

DIAMETER CALCULATION:

Adopting the methodology as given in RICHARDSON AND COULSON,VOLUME 6,

First we calculate,

>/*@ [ ^ !G !L) }0.5

= 0.0155 In the Literature given by RICHARDSON & COULSON, Pg 544

From the Plot of K4 9V >/*@ [ ^ !G !L) }0.5 K4 at flooding line = 6.1

Lets choose the following packing, as given in RICHARDSON & COULSON, Pg 533

Material = 3 Ceramic, Raschig Rings Nominal Size = 76 mm Bulk Density = 561 Kg/m3 Surface Area = 69 m2/m3 Packing Factor = 65 m-1 Voidage = 75% Then, G* = [ {K4 [ !G !L !G )} / {13.1 x Fp [ !L L)-0.1}]0.5 = [ {6.1 x 1.0711

( 1850

- 1.0711

)} / {13.1 x 65 x (6 x 10-3

/ 1850)0.1}]0. 5 = 7.08 Kg/m2-s

Designing for a Pressure Drop of 42 mm water per m of packing, we have

K4 = 1.9 Then, % Loading = {1.9 / 6.1}0.5 x 100% = 56 % And, G* = 3.95 Kg/m2-s

Then, Cross Section Area Required, A = [Mass Flow Rate] / G*

= 37.08 / 3.95 = 9.38 m2 Thus, Di = [{4 x 9.38 }/@ 0.5 = 3.45 m

Hence the Diameter which is calculated from this approach is 3.45 m

HEIGHT OF PACKING CALCULATION:

L = 23.88 Kgs/s 'HQVLW\ !L) = 1850 Kg/m3 GV = 37.08 Kgs/s 'HQVLW\ !G) = 1.0711 Kgs/m3

Volumetric Flow rate of the entering gas is given by, Gv = [37.08 / 1.0711] = 34.62 m3/s

Gas Velocity at the bottom of the tower is given by, Vbg = 34.62 / 9.38 = 3.69 m/s

Mass Flow Rate at the top of the tower is given by, GT = [ 3727.51 x 33.6 ] / 3600 = 34.79 Kgs/s

Volumetric Flow rate at the top of the tower is given by, Gt = [34.79 / 1.0711] = 32.48 m3/s Gas Velocity at the top of the tower is given by, Vbg = 32.48 / 9.38 = 3.46 m/s

Then Average Gas Velocity is given as,

Vavg = 3.57 m/s

And, Average Gas Velocity in the Packing,

VP = 3.57 / 0.75 = 4.76 m/s

Liquid Flow = 23.88 / 9.38 = 2.54 Kgs/m2-s

Given that, Surface Area of Packing = 69 m2/m3 Liquid Density = 1850 Kg/m3

Then, Wetting Rate = 2.54 / [1850 x 69] = 1.9898 x 10-5 m3/m-s

The Above wetting rate is greater than the required minimum limit and this is adequate for wetting the packing.

The Methodology adopted for the calculation of Height of the Packing is referred from the literature by NORMAN W.S (ABSORPTION, DISTILLATION AND COOLING TOWERS), Pg 214.

The Average Properties of the gas at the temperature are given as follows,

'HQVLW\ RI WKH JDV PL[WXUH !G) = 1.0711 Kg/m3 9LVFRVLW\ RI WKH JDV PL[WXUH mix) = 2.772 x 10-5

Diffusivity of the gas (D) = 8.2 x 10-6 m2/s

Schimidt Number (NSc) mix >!G) x (D)] = 2.772 x 10-5 / [1.0711 x 8.2 x 10-6] = 3.15

As given in the literature, The Reynolds number is calculated for the Standard Wetted Wall Column having the diameter,

d = 0.083 ft = 0.0253 m

Reynolds Number (NRe) >!G x d x VP@ mix) = [1.0711 x 4.76 x 0.0253] / (2.772 x10-5) = 4654 Cited in the Reference NORMAN W.S (ABSORPTION, DISTILLATION AND COOLING TOWERS), Pg 212, the co-relation is,

kG x (RT/ VP) x (P/pBM [ ^mix >!G x D]}0.5 = [ ^>!G x d x VP@mix)}-0.25

Now, With (P/pBM) =1(approx), we have,

kG = [ 0.04 x (4654)-0.25 x (3.15) -0. 5 x 15.61 x 3600 ] / {1.318 x 368} = 0.316 lb mole / hr-ft2-atm

Also given in the table of NORMAN W.S (ABSORPTION, DISTILLATION AND COOLING TOWERS), Pg 210 & Pg 211

For the conditions specified above the partial pressure of SO3 in equilibrium with the acid is extremely small and it may be assumed that the absorption is controlled by gas film.

Partial Pressure of SO3 in the gas at inlet,p1= 0.1016 Partial Presure at the Outlet, p2 = [0.1016 x 0.0423]/[0.8984+0.1016x 0.0423] = 4.76 x 10-3 Mean Driving Force = [ S1 - S1] / ln [ S1 / S1]

= 0.0316 atm

SO3 absorbed = 19657.5 / ( 80 x 0.454) lbmoles = 541.71 lbmoles/ hr

Area of Packing = 541.71 / (0.31 x 0.0316) = 55300 ft2 = 5140 m2

Area of Packing/ft height = 69 x 9.38

= 647.22

Height of Packing Required = 5140 / 647.22 = 7.94 m

Therefore the height of the packing required is 8m

MECHANICAL DESIGN OF ABSORBER

Inner Diameter of vessel, Di = 3.45 m Height of the packing required = 8m Skirt height = 2m Density of material column = 7700 Kg/m3 Wind pressure = 130 Kg/m2

MATERIAL :

Carbon Steel Permissible tensile stress ( f

)= 950kg/cm2

THICKNESS OF SHELL:

Thickness of shell, ts = [p D / (2f J p)] + c Where, Inner Diameter of vessel, Di = 3.45 m Working Pressure = 1.013 x105 N/m2 Design Pressure, p = 1.05 x 1.013 x105 N/m2 = 0.10635 N/mm2 Permissible Stress = 95 N/mm2 Joint Efficiency(J) = 0.85 Corrosion allowance = 3mm Hence, ts =2.25 mm

We take thickness as 8mm

So outer diameter of shell Do = 3.45 m + 2 x 0.008m = 3.466 m

STRESS ANALYSIS AND SHELL THICKNESS AT DIFFERENT HEIGHTS:

Let X be the distance in m from the top of the shell, then

1. AXIAL STRESS DUE TO PRESSURE

Axial stress due to pressure, fap = p Di / 4 ( ts c ) = 184 Kg/cm2

2. STRESS DUE TO DEAD LOAD a) Compressive Stress due to weight of shell up to a distance X

Outer Diameter Of shell = Di + 2 ts

= 3.466 m Density of Shell material, s = 7700 Kg /m3 fds = /4 ( Do2 Di2 )s X] / /4 ( Do2 Di 2 ) = 0.77 X Kg/cm2

b) Compressive stress due to weight of insulation at height X

Material for Insulation = Asbestos Thickness of insulation, tins = 100 mm Density of insulation = 575 Kg/m3 Let, Dins = Diameter of insulation, Dm = Mean diameter of vessel And, For large diameter column, Dins = Dm

fdins = [ Dins tins ins X] / { Dm ( ts c )} = 1.15 X Kg /cm2

c) Compressive stress due to liquid in column up to height X

Density of liquid, l = 1850 Kg/m3 fdliq = [ ( /4 ) Di2 X l ]/ Dm ( ts c ) = 3.19 x106 N/m2 = 31.9 Kg/cm2

d) Compressive stress due to attachment

We have the following attachments in the absorber column Piping weight Head weight Ladder

Head weight (approximately) = 2500 Kgs

Weight of Ladder = 160 X Kgs

Total compressive stress due to attachments fd is given by,

fd(attachments) = (Piping Weight + Head Weight + Ladder)/[ Di ( ts c )] = (2500 + 160X) / ( x 0.5 x 345) = 4.613 + 0.295 X Kg/cm2

e) Stress due to Wind

fw = [ 1.4 x 130 x X2 [ @ > [ 3450 x 5 ] = 0.3358 X2 Kg/cm2

To determine the value of X

Permissible Stress = 95 N/mm2 And,

ftmax = fwx + fap fdx

Or, 0.3358 X2 (36.513 + 2.215X ) + 184 950 x 0.85 = 0

Or, 0.3358 X2 2.215 X - 660.01 = 0

Solving the above equation, We get, X = 47.752 m

SUPPORT FOR ABSORBER

Skirt support is used to support the absorber column.

Material to be used = Structural steel ( IS 800) Inner Diameter of the vessel, Di = 3.45 m Outer Diameter of the vessel, Do = 3.466 m Height of the Packing, = 8 m Density of carbon steel, s = 7700 kg /m3

Total weight = Weight of vessel + Weight of Attachments

= (/4) ( Do2 Di2) x H x s x 9.81 + ( /4) Di2 x H x l x 0.6 + ( /4) Di2 x H x p + 35000N + 1600 x H = 1.422 x10 7 N Diameter of Skirt = 3.45 m Considering the height of Skirt is 8m Wind Pressure is 1285 N/m2 Stress due to Dead Weight Thickness of the skirt support is tsk Stress due to dead load fd = Total Weight / Ds tsk = 9.302 x 10 5 N/m2

Due to wind load The forces due to wind load acting on the lower and upper parts of the vessels are determined as

plw = k p1 h1 Do puw = k p2 h2 Do Where K is coefficient depending on the shape factor. k=0.7 for cylindrical surface p1 is wind pressure for the lower part of the vessel. p2 is wind pressure for the upper part of the vessel p1 = 700 N /m2 p2 = 2000 N /m2 h1=20m h2 =14 m plw = k p1 h1 Do = 47686.8 puw = k p2 h2 Do = 149872.8 Bending moment due to wind at the base of the vessel is determined by Mw =plw (h1/2) + puw ( h1 + h2 /2) =4.09 x 10 6 Nm fwb = 4 x Mw / Do tsk =10.71 x10 7 /tsk

Stress due to Seismic Load Load F= CW W is total Weight of vessel C is Seismic Coefficient C=0.08 fsb = ( 2/3)[ CWH/ Rok2 tsk] Where, Rok is radius of skirt = 4.159 x 10 6 /tsk N/m2

Maximum Stress at bottom of Skirt ftmax = ( fwb or fsb ) fdb = (3.229 x 10 6 / tsk ) N / m2

Permissible tensile Stress for structural steel = 140 N/mm2 tsk = 0.023m Hence thickness of skirt is 23 mm

Maximum Compressive Stress fcmax = ( fwb or fsb ) + fdb = (5.089 x 10 6 / tsk ) N /m2 Yield point = 200 N / mm2 fc permissible

Maximum Compressive Stress between bearing plate and foundation fc= Total Weight /A + Mw /2 Dsko = 5 .018m Dski = 4.866m A = ( /4) ( Dsko2 Dski 2) fc = 6.911 x 10 6 N / m2 F = (3 x fc x L2) / tb2 Permissible stress F in bending is 157.5 N/mm2 tb = 118 mm Anchor Bolt, Wmin=7.86 x 10 5 N (assumed) Fc = (Wmin/ A ) (Mw /Z) = - 9.9 x 10 5 N /m2 Fc is - ve , vessel skirt must be anchored to the concrete foundation by anchor bolt Number of bolt = 4.866 x 10 3 / 600 = 32 Pbolt = (fc) min x A) / N = 3.11 x 10 5 N

HEAT EXCHANGER

PROCESS DESIGN OF HEAT EXCHANGER:

BASIS:

1 HOUR OF OPERATION

GIVEN:

THE FLUIDS ARE:

WATER:

INLET TEMPERATURE = 25 C OUTLET TEMPERATURE = 40 C

SULFURIC ACID:

INLET TEMPERATURE = 112 C OUTLET TEMPERATURE = 30 C

The Sulfuric acid coming out from the absorption towers are cooled from a high temperature to a lower temperature in a Shell and Tube Type Heat Exchanger. Water which enters the Heat Exchanger at room temperature is heated to 40 C and comes out of the system.

BULK TEMPERATURE OF THE ACID = (30 + 112)/2 = 71.0 C

PROPERTIES OF WATER AT BULK TEMPERATURE OBTAINED FROM THE LITERATURE ARE AS FOLLOWS:

PROPERTIES

NUMERICAL VALUE

1. BULK TEMPERATURE OF WATER 32.5 C '(16,7

PROPERTIES OF SULFURIC ACID AT BULK TEMPERATURE OBTAINED FROM THE LITERATURE ARE AS FOLLOWS:

PROPERTIES

NUMERICAL VALUE

1. BULK TEMPERATURE OF WATER 71 C '(16,7

3. ROUTING:

Shell Side = Sulfuric Acid Tube Side = Cooling Water

4. DETERMINATION OF AREA:

Assume Uo = 630 W/m2-K Then, Area can be calculated as, A = 1596.7 x 103 / [630 x 20.94] = 121.03 m2

5. CHOICE OF TUBES:

From the tubing characteristics as given in PERRY, We choose the following dimensions of the tube,

1 inch Outer Diameter tubes with 1.25 inch Triangular Pitch,16BWG

Do = 1.0 inch = 25.4 mm Di = 0.87 inch = 22.1 mm P = 31.75 mm

Let us assume the tube to be of length of 6m. Number of tubes [ [

= 253

6. CORRECTION OF HEAT TRANSFER AREA:

From the tube count table, We have For TEMA P or S (1- 4 Exchanger) 1 Shell Pass and 4 Tube Passes Diameter of Shell, Ds = 635 mm Number of Tubes, Nt = 250

Corrected HT Area [ [ [ = 119.69 m2

Corrected Uoc = 637.07 W/m2-K

7. CALCULATION OF INSIDE HEAT TRANSFER COEFFICIENT

Area of the tubes, at > [ Gi2 x Nt ] / [ 4 x NP ]

= 0.024 m2 Mass velocity Gst = 25.42 / 0.024 = 1059.16 Kg/m2-s

Velocity inside the tubes, Vt P > ! [ Dt ] = 1059.16 / 994.865 = 1.06 m/s

The above velocity is also within acceptable limits of 1 to 3 m/s.

Reynolds Number, NRe = [Gst x di @ = [1059.16 x 22.1 x 10-3 ] / 0.8 x 10-3 = 29260

Prandtl Number, NPr = 5.37

(hi di / k) = jH x (NRe) x (NPr)(1/3) where, jH = 0.0036 Then,

(hi di / k) = 184.45 hi = 5199 W/m2 K

8. CALCULATION OF OUTSIDE HEAT TRANSFER COEFFICIENT

Length of tube L = 6 m Baffle Spacing, Ls = 0.266 x Ds = 168.9 mm Number of baffles, Nb +1 = 6 / Ls

Nb = 35

Sm = [ Ls (P- Do) Ds ] / P = [(0.03175 0.0254) x 0.1689 x 0.635 / 0.03175 = 0.02145 m2

vs = mh / (Sm [ !h) = {48572/3600} / (0.02145 x 1850) = 0.340 m/s

The above value of velocity is also in the range of 0.3 to 1m/s, so this is also acceptable.

Equivalent Diameter, de = 1.1 {31.752 0.917 x 25.42 }/ 25.4 = 18.04 mm

NRe = [de *@ = [ 629 x 18.04 x 10 -3 ] / 6.83 x 10-3 = 1661

NPr = 42.9

From the graph, we have jH = 0.019

(ho de / k) = jH (NRe) (NPr)(1/3) w)0.14 = 103.65

ho = 3763 W/m2 K

[ 1 / Uo ] = [ 1 / ho ] + [ Do / Di ] [ 1 / hi ] + [Do x ln {Do/Di} / (2Kw)] + [ 1 / hod ] + [ Do / Di ] [ 1 / hid ]

Taking, [ 1 / hod ] = 1 / 3000 (m2-K)/W [ 1 / hid ] = 1 / 5000 (m2-K)/W

[ 1 / Uo ] = 1.083 x 10-3 (m2-K)/W

Uo = 923 W/(m2-K)

Note: As this value of Uo is greater than the corrected value of Uoc, so the design with the above specifications is accepted.

9. PRESSURE DROP CALCULATION:

For Tube side,

f = 0.079 x (NRe)-0.25 = 0.00604

3L = [(4fLVt2 [ !f ] / {2 x Di} = 3666 N/m2

3t [ >!f x Vt2 / 2] = 1397 N/m2

3T = Np 3L 3t) = 20252 N/m2 = 20.25 KPa

Note: As the value of the pressure drop is less than 70KPa, the design is acceptable from the tube side pressure drop consideration.

For Shell Side,

Pressure Drop in the Cross Flow section is calculated by,

3c = [{b x fK x W2 x Nc ` !f x Sm2 @ [ ^w b}0.14 KN/m2

NRe = 1668 b = 2 x 10-3 fK = 0.25

!h !f) = 1850 Kg/m3 mh(W) = 13.49 Kg/s

Nc = [ Ds ( 1 2 {Lc/Ds} ) / Pp ] = 635 x (1-2 x 0.25) / 22 = 14.43 = 14.5

3c = [{2 x 10-3 x 0.25 x 13.492 x 15}/( 1850 x 0.021452)] KN/m2 = 1.55 KPa

Pressure Drop in End Zones is calculated as,

3e 3c ( 1 + {Ncw / Nc} ) KN/m2

Ncw = 0.8 lc / Pp = [0.8 x 0.25 x 635] / 22 = 6

3e = 1.55 [1 + ( 6 / 14.5 )] = 2.191 KPa

Pressure Drop in Window Zones

3w = [ b x W2 x ( 2 + 0.6 Ncw ) / { Sm x Sw [ !f }] KN/m2

b = 5 x 10-4 Sw = Swg - Swt

From the graph from PERRY Fig. 10-18, Pg. 10-29

Swg = 100 inch2 = 0.0645 m2 Swt = ( Nt / 8 ) x ( 1 Fc [ [ 'o2

From the graph from PERRY Fig. 10-16, Pg. 10-28

Fc = 0.65 Swt = (250 / 8) x ( 1 0.6 [ [ 2 = 0.0222 m2

Sw = Swg - Swt = 0.0645 0.0222 = 0.0423 m2

3w = [ 5 x 10-4 x 13.492 x ( 2 + 0.6 x 6 ) / {0.02145 x 0.0423 x 1850}] = 0.303 KPa

Therefore the total Pressure Drop on the shell side is calculated by the following relation

3s (TOTAL) [ 3e + (Nb [ 3c + Nb [ 3w = 2 x 2.191 + 35 x 1.55 + 36 x 0.303 = 69 KPa

As this value of Pressure Drop on the shell side is less than the 70 KPa, the design is acceptable from the Pressure Drop Point of View.

Thus, the design is acceptable from process design consideration.

SUMMARY OF PROCESS DESIGN FOR HEAT EXCHANGER

Mass flow rate of acid = 13.49 Kg/s Mass flow rate of water = 25.42 Kg/s Shell outer diameter = 635 mm Number of tubes = 250 Tube OD = 1 inch Pitch (Triangular) = 1.25 inch Tube length = 6 m Shell side pressure drop = 69 KPa Tube side pressure drop = 20 KPa Heat Exchanger type = TEMA P or S type 1-4 Heat Exchanger

MECHANICAL DESIGN OF HEAT EXCHANGER

Working Pressure = 1 atm Inlet Temperature = 110 C Design pressure = 1.1 atm Number of tubes = 250 Shell diameter = 635 mm

The entire mechanical design is referred from the literature in PROCESS EQUIPMENT DESIGN by M.V JOSHI.

1. SHELL THICKNESS

Material: IS 2825-1969 Grade I plain Carbon steel.

Shell thickness , (tS) = [{P x Di }/ ( 2fJ P )] = [{635 x 1.1} / (2 x 95 x 0.85 1.1)] = 4.29 cm = 5 mm

From the Table 9.2, its found that minimum shell thickness when severe conditions are not expected is 8mm, which includes the Corrosion Allowance.

2. NOZZLES

Take inlet and outlet nozzles as 100mm diameter.

Vent nozzle = 25mm diameter Drain nozzle = 25mm diameter Relief Valve = 50 mm diameter. Nozzle thickness = [ P x Di ] / { 2 f J - P } = 0.68 mm

Minimum nozzle thickness is 6mm and 8mm is choosen which includes the corrosion allowance.

Also only the inlet and outlet nozzles need compensation. The compensation required is minimum and is given by pads of 10mm thickness.

3. HEAD

Torispherical heads are taken for both ends.

Rc (Crown radius) = 635 mm

Rnk (knuckle radius) = 63.5 mm

Head thickness ( th ) = [ P x Rc x W ] / { 2 f J } Where, W = (1/4) x [ 3 + (Rc / Rnk)0.5 ] = 1.54

Head thickness ( th ) = [ P x Rc x W ] / { 2 f J } Head thickness = 6.66 mm

Therefore we take Head Thickness as that of the Shell Thickness = 8mm

4. TRANSVERSE BAFFLES

Number of Baffles = 35 Baffle cut = 25% Baffle thickness = 6mm (standard)

5. TIE RODS AND SPACERS

Diameter of tie rods = 10mm Diameter of Spacers = 8mm

6. FLANGE DESIGN

Flange is ring type with plain face.

Flange material: IS 2004-1962 Class 2 Carbon Steel Bolting steel: 5% Chromium, Molybdenum Steel

Gasket Material: Asbestos

Shell OD = 0.635 m Shell Thickness = 0.008 m (g) Shell ID = 0.627 m

Allowable stress for flange material = 100 N/mm2 Allowable stress of bolting material = 138 N/mm2

6 (i). DETERMINATION OF GASKET WIDTH

Minimum design yield seating stress , y = 52.386 N/mm2 Gasket factor, m = 3.75 Gasket Size: Outer Diameter = 680 mm

Inner Diameter = 650 mm Mean Gasket Diameter, G = 665 mm Minimum gasket width, Choose N = 30 mm. Basic gasket seating width, bo = 30/2 = 15 mm

Effective Gasket Seating Width, b = 2.5 x [bo]0.5

= 9.7 mm

6 (ii). ESTIMATION OF BOLT LOADS

Under atmospheric conditions, the bolt load due to gasket reaction is given by Wm1 = b G y = x 2 x 665 x 52.39 = 1061 KN

Load due to design pressure Wm2 = H+HT Wm2 = G2P/4 + G(2b)mp = 549.23 KN

Wm1 > Wm2 Hence, the controlling load is Wm1

6 (iii). CALCULATION OF MINIMUM BOLTING AREA:

Am = Ao = W / S

S = allowable stress for bolting material

Am1 = Ao = 1061 x 103/138 = 7688.4 mm2

6 (iv). CALCULATION OF OPTIMUM BOLT SIZE.

Bolts are of 5% Cr Mo Steel

Number of bolts = G / [bo x 2.5] = 665 / [15 x 2.5] = 18 bolts Diameter of bolts = [(Am1 / Number of bolts ) x ( 4 / ) ]1/2 = 24 mm

7. FLANGE THICKNESS

Thickness of flange , tf = [G(p/Kf) ] + C

Where, C is the Corrosion allowance hG is radial distance from gasket load reaction to bolt circle Hydrostatic end force, H = ( /4) G2 p = 38.69 KN K =1/[ 0.3 + {( 1.5 Wm hG) / (H x G)}] hG = (B G )/2

Where, B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm = 680 + 2 x 24 + 12 = 740 mm Then, hG = (B G )/2 = 37.5 mm

K = 1/[ 0.3 + {( 1.5 Wm1 hG) / (H x G)}] = 0.382

tf = [G(p/Kf) ] + C = 35.8 + C = 38 mm Hence the thickness of flange = 38 mm

TUBE SIDE

Material:Stainless steel ( IS- grade 10)

Thickness of tube = tf = {P x Do} / ( 2 f J + P)

Where, Working pressure = 12 N/mm2 Design pressure, P = 14 N/mm2 Permissible Stress, f = 100.6 N/mm2 Joint Efficiency, J = 1 Thickness of tube = 1.65 mm Use tube with thickness of 2mm

No Corrosion allowance, since the tubes are of stainless steel.

1. TUBE SHEET The tube sheet is held between shell flange and the channel. The joint on the shell flange side is of male and female facing and on the channel side of ring facing, since the pressure on the channel

Thickness of Tube Sheet , tts = FG[(0.25 P)/f]

Where, F = 1.25 Thickness of tube sheet = 155 mm

2. CHANNEL AND CHANNEL COVER Material :Carbon Steel

Permissible stress,f = 95 N/mm2

For Ring type gasket K =0.3 Thickness of channel, th =G [(K x P) /f ] =140 mm

4. GASKET SIZE

Width of ring gasket, N = 30 mm

Gasket material: Steel Jacketed Asbestos

Gasket factor, m = 5.5 Minimum design seating stress, Ya = 126.6 N / mm2 Basic gasket seating width, bo = N / 8 = 30 / 8 = 3.75 mm

Effective gasket seating width,b = bo Mean diameter, G = 665 mm

Design pressure, P = 14 N/mm2

Under atmospheric conditions, the bolt load due to gasket reaction is given by

Wm1 = b G Ya = 991.8 KN

After the internal pressure is applied, the gasket which is compressed earlier, is released to some extent and the bolt load is given by

Wm2 = x 2 b x G x m x P + ( / 4 )G2 P = 6069 KN

f is permissible tensile stress in bolts under atmospheric condition

Bolt Material: 5%Cr Mo Steel, f

= 140.6 N/mm2

Am = area of bolt Am1 = Wm1 / fa

=

7075 mm2 Am2 = Wm2 / fb = 43165 mm2

Number of bolts = (mean diameter) / 10 x 2.5 = 26 bolts

To determine the size of bolts , the larger of above two areas should be considered

Diameter of bolts,Db = [( Am2 / Number of bolts ) x ( 4 / )]1/2 = 46 mm

5. THICKNESS OF NOZZLE

Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is given by,

Thickness of nozzle, tn = (P x Dn) / [2 x f J P] Permissible stress, f = 95 N/ mm2 Joint Efficiency, J = 0.85 Then, Thickness of nozzles =10 mm

6. FLANGE THICKNESS:

Flange material: IS 2004-1962 Class 2 Carbon Steel

Thickness of the Flange , tf = [G(P/Kf) ] + C Where, C is the Corrosion allowance Allowable stress for flange material, f = 100 N/mm2

hG is radial distance from gasket load reaction to bolt circle Hydrostatic end force, H = ( /4) G2 P = 4863 KN K =1/[ 0.3 + {( 1.5 Wm hG) / (H x G)}] hG = (B G )/2 Where, B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm = 680 + 2 x 46 + 12 = 784 mm

Then, hG = (B G )/2 = 60 mm K = 1/[ 0.3 + {( 1.5 Wm2 hG) / (H x G)}] = 2.1326 Then, tf = [G(P/Kf) ] + C = 170 + C = 175 mm

Hence the thickness of flange = 175 mm

SUPPORT FOR SHELL AND TUBE HEAT EXCHANGER

Length of the heat exchanger, L = 6000 mm Inner diameter of Shell, Di = 635 mm Outer diameter of Shell, Do = 643 mm Thickness of Shell, ts = 8 mm Outer diameter of tube, do = 25.4 mm Number of tubes, Nt = 250

Density of Steel,s = 7850 Kg /m3 'HQVLW\ RI /LTXLG LQ WXEHV !l = 1000 Kg /m3

Volume of Shell body, V = ( / 4) ( Do2 Di2 ) x L = 0.0482 m3

Weight of Shell body, Ws = V x s = 379 Kgs

Volume of Tubes, Vt = ( / 4 ) ( do2 di2 ) x L x Nt = 0.185 m3

Total Weight of Tubes, Wt = Vt x s = 1453 Kgs

Volume of Head, Vh = 0.087 Di3 = 0.022 m3

Weight of Head, Wh = Vh x s = 173 Kgs

Weight of Liquid, Wl = ( / 4) (di2) x L x N x l = 577 Kgs

Total Weight, W = Ws+ Wt + Wh + Wl = 2582 Kgs

= 25.82 KN Depth of head, H = 250 mm

Q = (W/2) = 12.91 KN-m Now, we calculate, Distance of saddle center line from shell end , A = 0.4 x Ri = 0.4 x (635/2) = 127 mm 1. LONGITUDINAL BENDING MOMENTS

Radius, R = 0.317 m Depth of head, H = 0.250 m

The bending moment at the supports is

M1 = QA [ 1 {(A/L)+ (R2 - H2) / 2 AL}/{1 + 4H/3L}] = 80.12 N-m

The bending moment at the center of the span is given by M2 = (Q L / 4)[{1+ 2 ( R2 - H2 ) / L2 }/{1+ 4H / 3L} - ( 4A / L) ] = 16745 N-m

2. STRESS IN SHELL AT THE SADDLE

For =120 k1 = 0.107 k2 = 0.192 Thickness of shell, t = 8 mm f1 = M1/( k1R2 t) = 297 x 103 N/m2 f2 = M1/( k2 R2 t) = 165.2 x 103 N/m2

3. STRESS IN THE SHELL AT MID- SPAN

The stress at the mid span is f3, which is either tensile or compressive depending on the position of the fiber. The resultant tensile stresses ( including the axial stress due to internal pressure ) should not exceed the permissible stress, and the resultant compressive stress should not exceed the permissible compressive stress

f3 = M2 /(R2 t ) =6.63 x 106 N/m2

Axial Stress in Shell due to internal pressure

fp = (P x Di )/ (4 t) = 2.262 x 106 N/m2 All combined stresses ( fp + f1 ) , ( fp + f2 ) , and ( fp + f3 ) are well within allowable limits. Hence, the given parameters can be considered for design.

Thus a shell and tube Heat Exchanger with the above specifications is designed.

COOLER

PROCESS DESIGN OF COOLER:

BASIS:

1 HOUR OF OPERATION

GIVEN:

THE FLUIDS ARE:

WATER:

INLET TEMPERATURE = 25 C OUTLET TEMPERATURE = 40 C

PROCESS GAS:

INLET TEMPERATURE = 202.41 C OUTLET TEMPERATURE = 110 C

The Process gas which consists of mixtures of Sulphur Dioxide, Sulfur Trioxide, Nitrogen (inert) and Oxygen are cooled from a high temperature to a lower temperature in a Shell and Tube Type Heat Exchanger. Water which enters the Heat Exchanger at room temperature is heated to 40 C and comes out of the system.

BULK TEMPERATURE OF THE GAS MIXTURE = (202.41 + 110)/2 = 156.20 C

PROPERTIES OF WATER AT BULK TEMPERATURE OBTAINED FROM THE LITERATURE ARE AS FOLLOWS:

PROPERTIES

NUMERICAL VALUE

1. BULK TEMPERATURE OF WATER 32.5 C '(16,7

For the Gas Mixture,

SPECIFIC HEAT CAPACITY, CPg = 1.041 KJ/Kg-K

PROPERTIES OF PROCESS GAS ARE PREDICTED AS MENTIONED BELOW:

Based on the Literature on TRANSPORT PHENOMENA BY BIRD, we have the following :

CALCULATION OF VISCOSITY OF GAS MIXTURE:

The Critical constants data are given

COMPONENT CRITICAL TEMPERATURE(K)

CRITICAL PRESSURE(ATM)

1. N2 126.2 33.5 2. O2 154.4 49.7 3. SO2 430.7 77.8 4. SO3 490.8 83.6

Bulk temperature = 154.29 + 273 = 427.29 K Pressure = 2.13 atm

COMPONENT TR (K) PR(ATM) 1. N2 3.380 0.06358 2. O2 2.760 0.04285 3. SO2 0.990 0.02730 4. SO3 0.870 0.02550

c for each component is then calculated by the equation as, c = 7.7 x (M)0.5 x (PC)(2/3) x (TC)(-1/6)

Where M is the Molecular weight Tabulating the Data that are obtained from the graph as well as from the calculation,

COMPONENT r (poise) c (poise) SRLVH 1. N2 1.6 1.89 x 10-6 3.024 x 10-4 2. O2 1.2 254.2 x 10-6 3.0504 x 10-4 3. SO2 0.45 408.5 x10-6 1.8380 x10-4 4. SO3 0.38 468.8 x 10-6 1.7810 x 10-4

COMPONENT MOLE FRACTION

MOLECULAR WEIGHT SRLVH

1. N2 0.8301 28 3.024 x 10-4 2. O2 0.0647 32 3.0504 x 10-4 3. SO2 0.0034 64 1.8380 x10-4 4. SO3 0.1016 80 1.7810 x 10-4

We tabulate the calculations,

i j (Mi / Mj ) i / j ) -ij [j -ij)

1 1 1.000 1.000 1.000 2 0.875 0.990 1.062 1.129 3 0.437 1.640 1.954 4 0.350 1.690 2.202

2 1 1.142 1.008 0.938 2 1.000 1.000 1.000 1.0625 3 0.500 1.659 1.850 4 0.400 1.710 2.089

3 1 2.285 0.607 0.521 2 2.000 0.602 0.557 0.5871 3 1.000 1.000 1.000 4 0.800 1.032 1.134

4 1 2.857 0.588 0.455 2 2.500 0.583 0.488 0.5142 3 1.250 0.968 0.878 4 1.000 1.000 1.000

In the above tabular column, the value of-ij is calculated by the equation,

-ij = (1/ [ > 0i / Mj )-0.5 @ [ > i / j )0.5 x (Mj / Mi )0.25 ] 2

mix > [i i [j -ij) ] = [{0.8301 x 3.024 x 10-4}/1.129] + [{0.06479 x 3.0504 x 10-4}/1.0625] + [{0.003467 x 1.838 x 10-4}/0.5871] + [{.1016 x 1.781 x 10-4}/0.5142] = 2.772 x 10-4 g-cm-1-s-1

= 2.772 x 10-5 Kg/ms

CALCULATION OF THERMAL CONDUCTIVITY:

COMPONENT Pr Tr Kc Kr K 1. N2 0.0635 3.380 1.024 x 10-4 1 1.024 x 10-4 2. O2 0.4285 2.760 9.459 x 10-5 0.78 7.370 x 10-5 3. SO2 0.0273 0.990 3.893 x 10-5 0.33 1.284 x 10-5 4. SO3 0.0255 0.870 4.025 x 10-5 0.28 1.127 x 10-5

Kc is calculated from the relation given by,

Kc = [ CP 50 @ [

Where value of R is 1.987

Kmix > [i Ki [j -ij) ] = [{0.8301 x 1.024 x 10-4}/1.129] + [{0.06479 x 7.370 x 10-5/1.0625] + [{0.003467 x 1.285 x 10-5}/0.5871] + [{.1016 x 1.127 x 10-5}/0.5142] = 8.21 x 10-5 Cal / s-cm-K = 344.8 x 10-4 J/s-m-K

1. HEAT LOAD:

With, mg = 131518.5 Kg/Hr = 36.5 Kg/s

Q = mg x CPg [ >7@gas = 131518 x 1.041 x 103 x (202.41 110) = 12.65 x 109 J/Hr = 3.514 x 106 J/s

As the values of Mass Flow Rate (mg ) and Heat Load (Q) are on higher side, we split the entire flow rate into 4 equal parts so that we have 4 equal area heat exchangers operating in parallel and which are handling equal heat load. So, we have mg = 9.13 Kg/s Q = 878.5 x 103 J/s Overall Heat Balance gives, mw x 4187 x 15 = 878.5 x 103 mw = 13.98 Kg/s

2. LMTD: GAS MIXTURE WATER 7 TEMPERATURES 202.41 40 162.4 C

TEMPERATURES 110.0 25 85 C

LMTD =[(202.41-40)-(110-25)] / ln[(202.41-40)/(110-25)] = 119.5 C

R = [202.41-110] / {40-25} = 6.16 S = [40-25] / {202.41-25} = 0.0846 From the graph, we have FT = 0.98

Then, LMTD = 116.6 C

3. ROUTING:

Shell Side = Process Gas Tube Side = Cooling Water

4. DETERMINATION OF AREA:

Assume Uo = 200 W/m2-K Then, Area can be calculated as, A = 878.5 x 103 / [ 116.6 x 200] =37.67 m2

5. CHOICE OF TUBES:

From the tubing characteristics as given in PERRY, We choose the following dimensions of the tube,

0.75 inch Outer Diameter tubes with 1 inch Triangular Pitch

Do = 0.75 inch = 0.01905m Di = 0.62 inch = 0.01575m P = 0.0254m

Let us assume the tube to be of length of 2m. Number of tubes [ [ = 314.728

6. CORRECTION OF HEAT TRANSFER AREA:

From the tube count table, We have For TEMA L or M (1-6 Exchanger) 1 Shell Pass and 6 Tube Passes Diameter of Shell, Ds = 540mm

Number of Tubes, Nt = 320

External Area = 0.0598 m2/m length Corrected HT Area = 0.0598 x (2 0.05) x 320 = 37.31 m2

Corrected Uoc = 878.5 x 103 / (37.31 x 116.6) = 201.93 W/m2-K

7. CALCULATION OF INSIDE HEAT TRANSFER COEFFICIENT

Flow area available per pass, at > [ Gi2 x Nt ] / [ 4 x NP ] = 0.01039 m2

Velocity inside the tubes, Vt P > ! [ Dt ] = 13.98 / [ 994.86 x 0.01039 ] = 1.3524 m/s

Reynolds Number, NRe = [ 994.86 x 0.01575 x 1.3524 ] / 0.8 x 10-3 = 26488

Prandtl Number, NPr = 5.37

(hi di / k) = 0.023 (NRe)0.8 (NPr)(1/3) = 139 hi = 5498 W/m2 K

8. CALCULATION OF OUTSIDE HEAT TRANSFER COEFFICIENT

Length of the tube, L = 2m Let, the number of baffles, Nb = 1

Nb +1 = L / Ls

Ls = 1

Sm = [ Ls (P- Do) Ds ] / P = [(0.0254 0.01905) x 0.540] / 0.0254 = 0.135 m2

G = Ws / Sm = 9.13 / 0.135 = 67.64 Kg/m2-s

!s = PM / RT = (2.13 x 33.6) / (0.082 x 429) = 2.044 Kg/m3

NRe '* = [ 0.01905 x 67.64 ] / 2.772 x 10-5 = 46484

NPr = 0.8368

From the graph, we have j = 4 x 10-3

(ho do / k) = j (NRe) (NPr)(1/3) = 175.1

ho = 316.7 W/m2 K

[ 1 / Uo ] = [ 1 / ho ] + [ Do / Di ] [ 1 / hi ] + [Do x ln {Do/Di} / (2Kw)] + [ 1 / hod ] + [ Do / Di ] [ 1 / hid ]

Taking, [ 1 / hod ] = 1 / 3000 (m2-K)/W [ 1 / hid ] = 1 / 5000 (m2-K)/W

[ 1 / Uo ] = 3.99 x 10-3 (m2-K)/W

Uo = 250.47 W/(m2-K)

Note: As this value of Uo is greater than the corrected value of Uoc, so the design with the above specifications is accepted.

9. PRESSURE DROP CALCULATION:

For Tube side,

f = 0.079 x (NRe)-0.25 = 6.193 x 10-3

3L = [(4fLVt2 [ !f ] / {2 x Di} = 2851.08 N/m2

3t [ >!f x Vt2 / 2] = 2266.06 N/m2

3T = Np 3L 3t) = 30702.8 N/m2 = 30.7 KPa

Note: As the value of the pressure drop is less than 70KPa, the design is acceptable from the tube side pressure drop consideration.

For Shell Side,

Pressure Drop in the Cross Flow section is calculated by,

3c = [{b x fK x W2 x Nc ` !f x Sm2 @ [ ^w b}0.14 KN/m2

NRe = 46484 b = 2 x 10-3 fK = 0.12 !v !f) = 2.044 Kg/m3 mg(W) = 9.13 Kg/s

Nc = [ Ds ( 1 2 {Lc/Ds} ) / Pp ] = 540 x (1-2 x 0.25) / 22 = 12.27

3c = [{2 x 10-3 x 0.12 x 9.132 x 12.27}/( 2.044 x 0.1352)] KN/m2 = 6.6 KPa

Pressure Drop in End Zones is calculated as,

3e 3c ( 1 + {Ncw / Nc} ) KN/m2

Ncw = 0.8 lc / Pp = [0.8 x 0.25 x 540] / 22 = 5

3e = 6.6 [1 + ( 5 / 12.27 )] = 9.28 KPa

Pressure Drop in Window Zones

3w = [ b x W2 x ( 2 + 0.6 Ncw ) / { Sm x Sw [ !f }] KN/m2

b = 5 x 10-4 Sw = Swg - Swt

From the graph from PERRY Fig. 10-18, Pg. 10-29

Swg = 75 inch2 = 0.04838 m2 Swt = ( Nt / 8 ) x ( 1 Fc [ [ 'o2

From the graph from PERRY Fig. 10-16, Pg. 10-28

Fc = 0.65 Swt = (320 / 8) x ( 1 [ [ 2 = 0.01596 m2

Sw = Swg - Swt = 0.04838 0.01596 = 0.03242 m2

3w = [ 5 x 10-4 x 9.132 x ( 2 + 0.6 x 5 ) / { 0.135 x 0.03242 x 2.044 }] = 23.29 KPa

Therefore the total Pressure Drop on the shell side is calculated by the following relation

3s (TOTAL) [ 3e + (Nb [ 3c + Nb [ 3w = 2 x 9.28 + 1 x 23.29 = 41.856 KPa

As this value of Pressure Drop on the shell side is less than the 70 KPa, the design is acceptable from the Pressure Drop Point of View.

Thus, the design is acceptable from process design consideration.

SUMMARY OF PROCESS DESIGN FOR SINGLE COOLER

Mass flow rate of process gas = 9.13 Kg/s Mass flow rate of water = 13.98 Kg/s Shell outer diameter = 540 mm Number of tubes = 320 Tube OD = 0.75 inch = 0.01905 m Pitch (Triangular) = 1 inch = 0.0254 m Tube length = 2 m Shell side pressure drop = 41.86 KPa Tube side pressure drop = 30.7 KPa Cooler type = TEMA L or M type 1-6 Heat Exchanger

MECHANICAL DESIGN OF COOLER

Working Pressure = 0.101 N/mm2 = 1.03 Kg/cm2 Design Temperature = 150 C Design pressure = 0.1084 N/mm2 = 1.105 Kg/cm2 Number of tubes = 320 Shell diameter = 540 mm

The entire mechanical design is referred from the literature in PROCESS EQUIPMENT DESIGN by M.V JOSHI.

1. SHELL THICKNESS

Material: IS 2825-1969 Grade I plain Carbon steel.

Shell thickness , (tS) = [{P x Di }/ ( 2fJ P )] = [{540 x 1.105 } / (2 x 950 x 0.85 1.105)] = 0.37 cm = 3.7mm

From the Table 9.2, its found that minimum shell thickness when severe conditions are not expected is 8mm, which includes the Corrosion Allowance.

2. NOZZLES

Take inlet and outlet nozzles as 100mm diameter.

Vent nozzle = 25mm diameter Drain nozzle = 25mm diameter Relief Valve = 50 mm diameter. Nozzle thickness = [ P x Di ] / { 2 f J - P } = 3.72mm

Minimum nozzle thickness is 6mm and 8mm is choosen which includes the corrosion allowance.

Also only the inlet and outlet nozzles need compensation. The compensation required is minimum and is given by pads of 10mm thickness.

3. HEAD

Torispherical heads are taken for both ends.

Rc (Crown radius) = 540 mm Rnk (knuckle radius) = 54 mm

Head thickness ( th ) = [ P x Rc x W ] / { 2 f J } Where, W = (1/4) x [ 3 + (Rc / Rnk)0.5 ] = 1.54

Head thickness = 4.836 mm Therefore we take Head Thickness as that of the Shell Thickness = 8mm

4. TRANSVERSE BAFFLES

Number of Baffles = 1 Baffle cut = 25% Baffle thickness = 6mm (standard)

5. TIE RODS AND SPACERS

Diameter of tie rods = 10mm Diameter of Spacers = 8mm

6. FLANGE DESIGN

Flange is ring type with plain face. Design pressure = 0.1084 N/mm2 (external)

Flange material: IS 2004-1962 Class 2 Carbon Steel Bolting steel: 5% Chromium, Molybdenum Steel

Gasket Material: Asbestos

Shell OD = 0.540 m Shell Thickness = 0.008 m (g) Shell ID = 0.532 m

Allowable stress for flange material = 100 N/mm2 Allowable stress of bolting material = 138 N/mm2

6 (i). DETERMINATION OF GASKET WIDTH

dO/di = [(y-Pm)/(y-P(m+1))]0.5

Assume a gasket thickness of 1.6mm Minimum design yield seating stress , y = 25.5 N/mm2 Gasket factor, m = 2.75 dO/di = 1.002 m

Let, di = B+10 = 0.550 m

Minimum gasket width, N = 0.550(1.002-1)/2 = 0.00055 m = 0.55 mm

Choose N = 40 mm.

do = 0.630 m

Basic gasket seating width, bo = 40/2 = 20 mm

Effective Gasket Seating Width, b = 2.5 x [bo]0.5

= 11.18

Diameter at location of gasket load reaction G = di + N = 0.590 m

6 (ii). ESTIMATION OF BOLT LOADS

Under atmospheric conditions, the bolt load due to gasket reaction is given by Wm1 = b G y = x 2 x 590 x 25.5 = 94.53 KN

Load due to design pressure

H = G2P/4 = 29.64 KN where P is the design pressure

Load to keep joint tight under operation:

Hp = G(2b)mp = x (590) x (4) x (2.75) x (0.1084) = 2.210 KN

Total Operating Load,Wm2 = H+HT = 31.85 KN

Wm1 > Wm2 Hence, the controlling load is Wm1

6 (iii). CALCULATION OF MINIMUM BOLTING AREA:

Am = Ao = W / S = 94.53 x 103/ S

S = allowable stress for bolting material

Am = Ao = 94.53 x 103/138 = 685mm2

6 (iv). CALCULATION OF OPTIMUM BOLT SIZE.

Bolts are of 5% Cr Mo Steel

Number of bolts = G / [bo x 2.5] = 590 / [20 x 2.5] = 12 bolts Diameter of bolts = [(Am / Number of bolts ) x ( 4 / ) ]1/2 = 9 mm

7. FLANGE THICKNESS

Thickness of flange , tf = [G(p/Kf) ] + C

Where, C is the Corrosion allowance hG is radial distance from gasket load reaction to bolt circle Hydrostatic end force, H = ( /4) G2 p = 29.63 KN K =1/[ 0.3 + {( 1.5 Wm hG) / (H x G)}] hG = (B G )/2

Where, B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm = 630 + 2 x 9 + 12 = 660mm Then, hG = (B G )/2 =0.035 m

K = 1/[ 0.3 + {( 1.5 Wm1 hG) / (H x G)}] = 1.713

tf = [G(p/Kf) ] + C = 14.8 + C = 20 mm Hence the thickness of flange = 20 mm

TUBE SIDE

Material:Stainless steel ( IS- grade 10)

Thickness of tube = tf = {P x Do} / ( 2 f J + P)

Where, Working pressure = 12 N/mm2 Design pressure, P = 14 N/mm2 Permissible Stress, f = 100.6 N/mm2 Joint Efficiency, J = 1.0 Thickness of tube = 1.24mm Use tube with thickness of 2mm

No Corrosion allowance, since the tubes are of stainless steel.

1. TUBE SHEET The tube sheet is held between shell flange and the channel. The joint on the shell flange side is of male and female facing and on the channel side of ring facing, since the pressure on the channel

Thickness of Tube Sheet , tts = FG[(0.25 P)/f]

Where, F = 1.25 Thickness of tube sheet = 140 mm

2. CHANNEL AND CHANNEL COVER Material :Carbon Steel

Permissible stress,f = 95 N/mm2

For Ring type gasket K =0.3 Thickness of channel, th =G [(K x P) /f ] =125 mm

4. GASKET SIZE

Width of ring gasket, N = 22 mm Inner diameter, Di = 0.550 m Outer diameter, Do = 0.630 m

Gasket material: Steel Jacketed Asbestos

Gasket factor, m = 5.5 Minimum design seating stress, Ya = 126.6 N / mm2 Basic gasket seating width, bo = N / 2 = 22 / 2 = 11 mm

Effective gasket seating width,b = 2.5 x (bo)0.5 = 8.3 mm Mean diameter, G = ( Di + Do) / 2 = 0.590 m

Design pressure, P = 14 N/mm2

Under atmospheric conditions, the bolt load due to gasket reaction is given by

Wm1 = b G Ya = 1948 KN

After the internal pressure is applied, the gasket which is compressed earlier, is released to some extent and the bolt load is given by

Wm2 = x 2 b x G x m x P + ( / 4 )G2 P = 6197 KN

f is permissible tensile stress in bolts under atmospheric condition

Bolt Material: 5%Cr Mo Steel, f

= 140.6 N/mm2

Am = area of bolt Am1 = Wm1 / fa

=

13855 mm2 Am2 = Wm2 / fb = 44075 mm2

Number of bolts = (mean diameter) / bo x 2.5

= 22 bolts

To determine the size of bolts , the larger of above two areas should be considered

Diameter of bolts,Db = [( Am2 / Number of bolts ) x ( 4 / )]1/2 = 51 mm

5. THICKNESS OF NOZZLE

Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is given by,

Thickness of nozzle, tn = (P x Dn) / [2 x f J P] Permissible stress, f = 95 N/ mm2 Joint Efficiency, J = 0.85 Then, Thickness of nozzles =10 mm

6. FLANGE THICKNESS:

Flange material: IS 2004-1962 Class 2 Carbon Steel

Thickness of the Flange , tf = [G(P/Kf) ] + C Where, C is the Corrosion allowance Allowable stress for flange material, f = 100 N/mm2

hG is radial distance from gasket load reaction to bolt circle Hydrostatic end force, H = ( /4) G2 P = 3827 KN K =1/[ 0.3 + {( 1.5 Wm hG) / (H x G)}] hG = (B G )/2 Where, B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm = 630 + 2 x 51 + 12 = 744 mm Then, hG = (B G )/2 = 77 mm K = 1/[ 0.3 + {( 1.5 Wm2 hG) / (H x G)}] = 1.620 Then, tf = [G(P/Kf) ] + C = 158 + C = 160 mm

Hence the thickness of flange = 160 mm

SUPPORT FOR SHELL AND TUBE HEAT EXCHANGER

Length of the heat exchanger, L = 2000 mm Outer diameter of Shell, Do = 556 mm Inner diameter of Shell, Di = 540 mm Thickness of Shell, ts = 8 mm Outer diameter of tube, do = 19.05 mm Inner diameter of tube, di = 15.75 mm Number of tubes, Nt = 320

Density of Steel,s = 7850 Kg /m3 Density of Liquid in tubes ,!l = 1000 Kg /m3

Volume of Shell body, V = ( / 4) ( Do2 Di2 ) x L = 0.0275 m3

Weight of Shell body, Ws = V x s = 216 Kgs

Volume of Tubes, Vt = ( / 4 ) ( do2 di2 ) x L x Nt = 0.0577 m3

Total Weight of Tubes, Wt = Vt x s = 453 Kgs

Volume of Head, Vh = 0.087 Di3 = 0.013 m3

Weight of Head, Wh = Vh x s = 102 Kgs

Weight of Liquid, Wl = ( / 4) (di2) x L x N x l = 124.6 Kgs

Total Weight, W = Ws+ Wt + Wh + Wl = 900 Kgs = 9.0 KN Depth of head, H = 220 mm

Q = (W/2) x (L+4H/3) = 10.32 KN-m Now, we calculate, Distance of saddle center line from shell end , A = 0.45 x Ri = 0.45 x (0.540/2)

= 121.5 mm 1. LONGITUDINAL BENDING MOMENTS

Radius, R = 0.270 m Depth of head, H = 0.220 m

The bending moment at the supports is

M1 = QA [ 1 {(A/L)+ (R2 - H2) / 2 AL}/{1 + 4H/3L}] = 171.68 N-m

The bending moment at the center of the span is given by M2 = (Q L / 4)[{1+ 2 ( R2 - H2 ) / L2 }/{1+ 4H / 3L} - ( 4A / L) ] = 3302 N-m

2. STRESS IN SHELL AT THE SADDLE

For =120 k1 = 0.107 k2 = 0.192 Thickness of shell, t = 8 mm f1 = M1/( k1R2 t) = 876 x 103 N/m2 f2 = M1/( k2 R2 t) = 488 x 103 N/m2

3. STRESS IN THE SHELL AT MID- SPAN

The stress at the mid span is f3, which is either tensile or compressive depending on the position of the fiber. The resultant tensile stresses ( including the axial stress due to internal pressure ) should not exceed the permissible stress, and the resultant compressive stress should not exceed the permissible compressive stress

f3 = M2 /(R2 t ) =1.80 x 106 N/m2 Axial Stress in Shell due to internal pressure

fp = (P x Di )/ (4 t) = 1.829 x 106 N/m2 All combined stresses ( fp + f1 ) , ( fp + f2 ) , and ( fp + f3 ) are well within allowable limits. Hence, the given parameters can be considered for design.

Note: This Cooler is fabricated 4 in number and are operated in parallel to take care of the Cooling duty required in the Process.